Skilled Production Manager

Thomas Abate

*** ******* **

Bozrah, CT *****

Phone 860-***-**** email: **********@*****.***

Experienced manager with strengths in production management, metals manufacturing, plastic injection molding, electronics assembly, ESD, naval power and propulsion assembly, aerospace support equipment assembly/manufacturing, assembly and manufacturing of power generation systems, design assembly testing of hybrid electric drives, wire and cable manufacturing, electro-mechanical assembly, project management, EHS compliance and reporting, program management, team management, team training, business development, financial management, materials management, quality management, multiple facilities management, production control, union negotiation, AutoCAD, Solidworks Viewer, team building, design development of fixturing, demand planning, J-STD soldering, auditing of AS9100, ISO 9001:2015 and ISO 14001.

SKILLS

LEAN, OpEx, 8d, Business Development, Process Flow Analysis, SAP, Project Design, Project / Program Management, Materials Management/Purchasing, EHS, RCCA, Kaizen, 6S, Auditing, Value Stream Mapping, Kanban, Industrial Engineering, Master Scheduling, Building Trust, Communication, Approachability, Interpersonal Skills, Listening Managing Priorities, Accountability, Decisiveness, Production/Result, Safety, Problem-Solving/Analysis, Risk Mitigation, Cross Functional Interface, Value Stream Management, Visual Factory Management

Management Experience

March 2022 – April 2023 (Plant Closed)

SSB Manufacturing Windsor Locks, CT Plant Manager

Managed day-to-day operations of manufacturing center with P&L responsibility of $58M.

Managed nine direct reports, including Production Manager, Materials Manager, Safety Manager, Quality Clerk, Maintenance Manager, Transportation and Planning Manager, Manufacturing Clerk, and Scheduling Clerk. HR Manager, Kaizen Manager

Responsible for all facility operations, staffing levels, training, and operational budgets.

Responsible for transportation and operation of 14 tractor-trailer teams.

Responsible for project bidding and proposals for new equipment and services.

Kaizen champion to improve the value stream.

Responsible for customer support and communications to the area network.

Key accomplishments:

Improved OTIF from 82% to 92%.

Reduced OSHA recordable by 50% - with a TRIR of 3.3

Reduced end-of-line quality defects by 23% thru kaizen activities.

Lifted productivity from 72% to 92% and came in under budget on total labor by $1.68 per unit.

Stabilized the manufacturing floor by promoting two leads to supervisor positions.

Improved facility communications with IT capital projects to wireless and server rooms.

Reduced raw material inventory by $1.2M

Reduced finished goods inventory by $500K

June 2019 – March 2022

SWPC Deep River, CT Plant Operations Manager – (Plant Closed)

Managed day-to-day operations of a 24-5, 52-machine plastic injections cost center (Including medical devices) with P&L responsibility of $53M.

Managed 150+ full-time employees and 12 direct reports, including Safety Supervisor, Shipping Supervisor, Purchasing Manager, Setup Engineer, Compliance Officer, Building Maintenance Supervisor, Machine Maintenance Supervisor, Sr Planner, Planner, and Production Supervisors.

Local Federal Firearms License holder and responsible for local ATF compliance.

Responsible for all facility operations, safety, training, staffing, and operational budgets.

Responsible for automation, process improvements to drive cost inistiatives.

Supported business development through sales contacts and engineering initiatives.

Responsible for the production of aerospace, medical, firearms, and commercial products.

Presented project plans, cost reduction, KPI, and team development initiatives to Executive Management.

Key accomplishments:

Improved processes with an overall saving of 800K in one year.

Reduced OSHA recordable to less than 1

Increasing OTD to greater than 97% on average.

Lifted overall machine utilization to 82%.

Improved overall performance of the plant to a profitability level of $1.5M when budgeted for an $850K loss.

Improved quality thru kaizen automation projects using collaborative robotics equipment.

June 2018 – June 2019

Porcelen Specrail LLC Hamden, CT Director of Operations

Managed day-to-day multi-facility operations of a $28M of Coil coating, metal finishing, paint line, powder coat line, welding shop, aluminum fabrication fence/railings, and gate manufacturing facility with full P&L resposibility.

Managed 50+ full-time employees and eight direct reports, including, Purchasing Manager, Shipping Supervisor, Purchasing Supervisor, Production Manager, Machine Maintenance Supervisor, Coil Line Manager, Welding Supervisor, and Customer Service Manager.

Responsible for all facility operations, staffing levels, operational budgets, and transportation trucks.

Key accomplishments:

Developed critical international supply chain efforts and business development efforts.

Rebuilt the MRP system of over 15,000 SKUs to include all BOM’s with accurate labor costing and packaging.

Purchased a new rail punching machine to reduce cycle times and increase the output of fence manufacturing lines.

Negotiated new purchasing agreements with overseas suppliers to reduce costs by 3%.

Maintained 90% OTIF metric.

Reorganized the planning and schedule of the company-owned delivery truck.

Worked with CT OSHA to improve the facility’s safety from previous OSHA findings.

May 2017 – June 2018

Rea Magnet Wire Guilford, CT Operations Manager

Managed day-to-day operations of a 24-5, 50-machine metals facility cost center with $61M.

Managed team of 74+ member IBEW union facility with seven direct reports, including Shift Supervisors, Shipping Supervisors, Planning Supervisors, Kaizen Supervisor, and Manufacturing Engineer.

Managed heat treatment and services for precision metals manufacturing.

Managed the manufacturing of metals used in medical equipment, transformers, aerospace, and automotive products,

Key Accomplishments:

Re-Organized master scheduling system for all operations.

Created and championed OpEx programs to increase area outputs and on-time delivery from 51% TO 92%.

Increased tape line area output by 19% using OpEx MBF strategies.

Champion of training to reduce cycle times by 25%.

Successfully proposed, moved, installed, and implemented CRE machine for wire manufacturing for electrical power distribution and medical devices.

Prepared budgets for future expansion projects and equipment purchases.

May 2015 – Feb 2017 SES America Inc.

Warwick, RI Operations/Materials Manager (Plant Closed)

Managed manufacturing operations of a $16M ITS, VMS, solar-powered electronic digital messaging sign corporation for DOT, Military, and private use.

Managed team 16 team members, including Design Engineer, Field Installation team, Production Supervisor, Quality Supervisor, Field Installation team, and Engineering Interns.

Key accomplishments:

Expertise as a Materials manager and engineering manager in developing (ITS) intelligent transportation

systems and bringing new products to market in less than 60 days.

Reduced cycle times in manufacturing to less than 90 days and increased customer satisfaction.

Successfully developed procedures and documentation for ISO 9000-2015 certification.

Implemented build book revisions for accurate assembly and reporting to adhere to DOT specifications.

Instituted a master scheduling system for all operations.

Instituted lean management with a focus on 6S and reducing cycle times.

Implemented lean product development and drove continuous improvement

Feb 2009 – May 2015 DRS Technologies (A Leonardo Company)

Fitchburg, MA – Hudson, MA Operations Manager

Managed 30+ operators, 2 Supervisors, and 3 team leaders of multiple aerospace/defense contracting facilities of a $63M+ electronics and $100M production environment integrating gas turbine military propulsion systems and various military/naval projects for both US and foreign navies.

Developed production and delivery schedules and developed productivity initiatives of modular propulsion systems, including PMM for Columbia Class Submarines.

Develop work packages to execute production efforts, procurement of components, receipt, and kitting of components, fabrication, assembly, quality checks, integration, testing, source inspection, acceptance of final product, and shipping/delivery of components for Virginia Class, Columbia Class, LCS, DDG-1000, DDG-51, and LHA.

Performed AS9100 and ISO 9001 audits for US Naval Systems Acceptance.

POC for DCMA inspections of (not limited to) electronic wiring, shipboard, and electronic safety requirements.

Introduced Lean and 6S initiatives to reduce cost and maintain on-time delivery.

Maintained a $400K+ overhead operating budget, managing the annual operational plan.

Directed field service testing maintenance and troubleshooting of electromechanical systems.

Managed building consolidation plans, facilities management, and security.

Managed proposals, bids, and acquisition of equipment for a PMM assembly project of more than $24M.

Presented project plans, cost reduction, KPI, and team development initiatives to Executive Management.

Developed quality control standards and metrics; Analyzes trends to continually improve Operational Efficiency Integration electromechanical sub-assemblies for installation into hybrid electric propulsion systems.

Key accomplishments:

Ensured a high level of accuracy with production and fulfillment - defect per unit to less than 1%

Improved EACs (Estimated Cost to Complete) by 25% on the GE LM2500 project.

Managed floor EHS improvements and reduced OSHA-recorded incidents to <1 on the EPA superfund site.

Actively controlled costs and reduced overhead budget by $150K

Managed and coordinated all floor tours and demonstrations to Executives, US Navy and International

Customers.

Created training programs and daily operations inspection programs.

100% On-Time Delivery on all US Naval Propulsion systems.

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DRS Technologies

Production Supervisor (Feb 2007 – July 2011) —Promoted to Operations Manager

Bridgeport, CT Facility

Managed 68 operators and 2 team leaders in $75M+ production environment building military generator sets.

Developed UPS product line for sales to the US State Department

Introduced Lean, 6S, and Six Sigma initiatives to reduce cost, followed all standards, and deliver high-quality

products on time.

Supervised tool crib and inventory stock levels.

Key accomplishments:

Lifted On Time Delivery from 74% to 99.8% in 2010.

Achieved the highest Customer (DCMA) quality rating in SW Connecticut.

Reduced overtime from 30% to <1% and reduced Defects per Unit to less than 1%.

Mentored and implemented a Safety Program that reduced Lost Time Work Incidents from 26 per year to zero in the last two quarters of 2010.

Led project teams to reduce defects through root cause analysis and reduced floor space requirements.

EDUCATION

BA Political Science – Western CT State University 2013, USAF Leadership School, The University of Central Florida - Effective Management Training 2010

MILITARY & CLEARANCES

SGT United States Air Force –Honorable Discharge, Formerly Held Secret and Top Secret–SCI clearance

CERTIFICATIONS

IPC J-STD J001-S SN#80873 ESD Control Certification Emmerson Surge Protector Certified ISO9001:2015

CCSU GD&T Certified Lean VFM 5S Plus 2

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